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Nitomortar HB*

constructive solutions

High build epoxy reinstatement mortar


Uses

Properties

For the fast and permanent reinstatement of concrete,


particularly for emergency repairs in vertical and overhead
situations. Typical applications would include, but not be
limited to, the following :

The following results were obtained at a temperature of 20C


unless otherwise specified.

! Where resistance to chemicals is required.


! Localised, lightweight patch repairs
For fast repairs to floors and other locations subjected to
wear and abrasion, the use of the associate product
Nitomortar S is recommended.
Advantages
! Lightweight formulation enabling extra high build and
thereby saving time and expense
! Obviates the need for formwork

Test method
Compressive strength
(BS 6319, Pt 2)
Flexural strength
(BS 6319, Pt 3)
Tensile strength
(BS 6319, Pt 7)
Compressive modulus
(ASTM C 469-65)
Pot Life
Initial hardness
Full cure
Fresh wet density

! Early development of strength minimises disruption


! Highly resistant - unaffected by a wide range of chemicals
! Extremely low permeability
! Equal to the strength of high quality concrete within
3 days
! Pre-weighed components ensure consistency
Description
Nitomortar HB is based on a high quality solvent-free epoxy
resin system. The special lightweight filler is specifically
designed to give excellent hanging properties for vertical
and overhead work. Nitomortar HB is a three-component
material supplied in pre-weighed quantities ready for on-site
mixing and use.
Design criteria

Nitomortar HB*

Nitomortar HB can be applied in sections up to 50 mm


thickness in vertical and overhead locations in a single
application and without the use of formwork. Thicker sections
up to 75 mm are possible in smaller locations, dependent
on the actual configuration of the repair area and the volume
of exposed reinforcing steel.
The material should not be applied at less than 10 mm
thickness. Greater thicknesses than those specified above
can be achieved by the application of subsequent layers.
Larger areas should be applied in a chequerboard fashion.
Consult the local Fosroc office for further information.
Where high compressive strength and abrasion resistance
is required, the use of Nitomortar S is recommended.

Chemical resistance

Typical result
:

40 N/mm2 @ 28 days

: 15 N/mm2 @ 28 days
: 7 N/mm2 @ 28 days
: 4.5 kN/mm2 @ 28 days
20C
35oC
: 45 mins
20mins
: 24 hours
16 hours
: 7 days
4 days
: Approximately 1160 kg/m3
(fully compacted)
: Performance of Nitomortar HB
blocks at 20C:

Acids (m/v)
Citric acid 10%
Tartaric acid 10%
Hydrochloric acid 25%
Sulphuric acid 10%
Lactic acid 10%
Phosphoric acid 10%
Nitric acid 10%
Acetic acid 5%

Resistant
Resistant
Resistant
Resistant
Resistant
Resistant
Resistant
Resistant

Alkalis (m/v)
Sodium hydroxide 50% - Resistant
Solvents & organics
Diesel fuel/petrol
Hydrocarbons 100%

- Resistant
- Resistant

Aqueous solutions
Saturated Sugar
Note :

- Resistant

Please contact your local Fosroc Office if the product


is being fully immersed.

Specification
Lightweight epoxy repair mortar
The lightweight repair mortar shall be Nitomortar HB, a
three-component epoxy resin with a density not greater than
1160 kg/m3. The cured mortar shall achieve a compressive
strength of 40 N/mm2, a flexural strength of 15 N/mm2 and a
tensile strength of 7 N/mm2 when tested at 28 days.

Nitomortar HB*
Instructions for use

Mixing

Preparation

Care should be taken to ensure that Nitomortar HB is


thoroughly mixed to produce a fully homogeneous, trowellable
mortar.

Clean the surface and remove any dust, unsound material,


plaster, oil, paint, grease, corrosion deposits or algae. Roughen
the surface and remove any laitance by light scabbling or gritblasting. Saw cut or cut back the extremities of the repair
locations to a depth of at least 10 mm to avoid feather-edging
and to provide a square edge. Break out the complete repair
area to a minimum depth of 10 mm up to the sawn edge.
Oil and grease deposits should be removed by steam cleaning,
detergent scrubbing or the use of a proprietary degreaser. The
effectiveness of decontamination should then be assessed
by a pull-off test.
Expose fully any corroded steel in the repair area and remove
all loose scale and corrosion deposits. Steel should be
cleaned to a bright condition paying particular attention to the
back of exposed steel bars. Grit-blasting is recommended for
this process.
Priming
Reinforcing steel priming
The cleaned steel should be coated within 3 hours. Apply one
full coat of Nitoprime Zincrich and allow to dry before continuing.
If any doubt exists about having achieved an unbroken coating,
a second application should be made and, again, allowed to
dry before continuing.
Substrate priming

The hardener and base components should be stirred


thoroughly in order to disperse any settlement before mixing
them together. The entire contents of the hardener and base
containers should then be emptied into the mixing vessel and
thoroughly mixed for 3 minutes.
While mixing continuously, the entire bag of aggregate should
then be added slowly and the three components blended
together for a further 2 to 3 minutes, ensuring that the aggregate
is thoroughly wetted out with the mixed resins. Under no
circumstances should part packs be used.
Multi-pack mixing is possible by using a forced action mixer of
suitable capacity e.g. Cretangle or Pennine.
Application
Apply the mixed Nitomortar HB to the prepared substrate by
wood float, pressing firmly into place to ensure positive
adhesion and full compaction. Thoroughly compact the mortar
around any exposed reinforcement.
In restricted locations, or where exposed reinforcing steel is
present, application by gloved hands is an acceptable
alternative but, in all cases, the product must be finished to a
tight surface with a steel trowel.
Nitomortar HB can be used in applications of up to 50 mm
thickness in vertical or overhead locations depending upon
the repair geometry. Thicker sections should be built up in
layers.

The substrate should be primed using Nitocote Primer Sealer.


The primer should be mixed in the proportions supplied, adding
the entire contents of the hardener tin to the base tin. The
two components should be thoroughly mixed together for 3
minutes.

When large areas are being repaired (generally over 2 m2) a


chequerboard application technique is recommended.

The mixed primer should be scrubbed well into the prepared


substrate, taking care that all imperfections in the surface are
properly coated, avoiding ponding in depressions. If the
Nitocote Primer Sealer is absorbed within 30 minutes, a
second coat should be applied before continuing.

It is sometimes possible for smaller repairs to be completed


in greater thicknesses, generally up to 75 mm, in a single
application dependent on the actual configuration of the repair
area and the volume of exposed reinforcing steel. If in doubt
regarding application, consult the local Fosroc office.

Nitomortar HB can be applied as soon as the primer has started


to gel but still has surface tack. This is normally between 30
minutes and 4 hours dependent on the ambient and substrate
temperatures. If Nitocote primer sealer cures hard, a second
application must be made before application of Nitomortar
HB. The usable life of the mixed primer is approximately 60
minutes at 20C or 30 minutes at 35C.

Note:

Nitomortar HB - Page 2 of 4

Minimum applied thickness of Nitomortar HB is


10mm.

Nitomortar HB*
Build-up
Additional build-up can be achieved by application of multiple
layers. Exposed steel reinforcing bars should be firmly
secured to avoid movement during the application process as
this will affect mortar compaction, build and bond.
Where thicker sections are required, the surface of the
intermediate applications should be scratch-keyed to provide
a suitable surface for subsequent layers. The application of
additional layers should follow between 8 and 24 hours (@ 20C)
after the first application. This time should be reduced at higher
temperatures. Repriming with Nitocote primer sealer and a
further application of Nitomortar HB may then proceed.
If sagging occurs during application, the Nitomortar HB should
be completely removed and reapplied at a reduced thickness
on to the correctly reprimed substrate.

The surrounding parts of the structure may benefit from the


application of a protective coating, thus bringing them up to
the same protective standard as the repair itself. Fosroc
recommend the use of the Nitocote range of epoxy resin,
chemical-resistant, protective coatings.
For surrounding areas not subjected to chemical attack or
physical wear, Fosroc recommend the use of the Dekguard
range of anti-carbonation, anti-chloride protective coatings.
These products provide a decorative and uniform appearance
as well as protecting areas of the structure which might
otherwise be at risk from the environment.
Nitocote epoxy resin protective coatings should be applied
within 24 hours. Dekguard products should not be applied
until the Nitomortar HB is at least 3 days old. For further advice,
consult the local Fosroc office.

Finishing

Limitations

Nitomortar HB is finished by the use of a wood float and closed


with a steel trowel wiped with a cloth dampened with Fosroc
Solvent 102. The completed surface should not be overworked.

Nitomortar HB should not be used when the temperature


is below 5C and falling.

Do not mix part packs under any circumstances.

Due to the lightweight nature of Nitomortar HB, the product


should not be used in areas subjected to traffic, point
loading or abrasion.

Nitomortar HB should not be exposed to moving water


during application. Exposure to heavy rainfall prior to the
final set may result in surface scour.

Curing
Curing is not necessary for Nitomortar HB.
Cleaning
Nitoprime Zincrich, Nitocote primer sealer and Nitomortar HB
should be removed from tools, equipment and mixers with
Fosroc Solvent 102 immediately after use.
High temperature working
At ambient temperatures above 35C, Nitocote primer sealer
and Nitomortar HB will have shorter pot lives and working lives.
The materials should be stored in the shade or in an airconditioned environment and should not be applied in direct
sunlight.
Overcoating with protective/decorative finishes
Nitomortar HB is extremely durable and resistant to a wide
range of acids, alkalis and industrial chemicals and will provide
excellent protection to the concrete and embedded steel
reinforcement within the repaired locations.

If any doubts arise concerning temperature or substrate


conditions, consult the local Fosroc office.
Technical support
Fosroc offers a comprehensive range of high performance,
high quality concrete repair and construction products. In
addition, Fosroc offers a technical support package to
specifiers, end-users and contractors, as well as on-site
technical assistance in locations all over the world.

Nitomortar HB - Page 3 of 4

Nitomortar HB*
Estimating

Precautions

Supply

Health and safety

Nitomortar HB
Nitoprime Zincrich
Nitocote primer sealer
Fosroc Solvent 102

:
:
:
:

10 litre packs
1 litre cans
1 and 4 litre packs
5 litre cans

1.0 m per pack


(at 10 mm thickness)
7.4 m2/litre
4.0 - 5.0 m2/litre

Coverage and yield


Nitomortar HB

Nitoprime Zincrich
:
Nitocote primer sealer :

Note: The coverage figures for Nitoprime Zincrich and Nitocote


primer sealer are theoretical - due to wastage factors
and the variety and nature of possible substrates,
practical coverage figures will be reduced.

Nitoprime Zincrich, Nitocote primer sealer, Nitomortar HB and


Fosroc Solvent 102 should not come in contact with skin or
eyes, or be swallowed. Ensure adequate ventilation and avoid
inhalation of vapours. Some people are sensitive to resins,
hardeners and solvents. Wear suitable protective clothing,
gloves and eye protection. If working in confined areas,
suitable respiratory protective equipment must be used. The
use of barrier creams provide additional skin protection. In
case of contact with skin, remove immediately with resin
removing cream followed by washing with soap and water.
Do not use solvent. In case of contact with eyes, rinse
immediately with plenty of clean water and seek medical
advice. If swallowed, seek medical attention immediately do not induce vomiting.
Fire

Storage

Nitomortar HB and Nitocote Primer Sealer are non-flammable..

Shelf life
All products have a shelf life of 12 months at 20C if kept in a
dry store in the original, unopened bags or packs.

Nitoprime Zincrich and Fosroc Solvent 102 are flammable.


Keep away from sources of ignition. No smoking. In the event
of fire, extinguish with CO2 or foam. Do not use a water jet.

Storage conditions

Flash points

Store in dry conditions in the original, unopened bags or packs.


If stored at high temperatures, the shelf life may be reduced to
4 to 6 months.

Nitoprime Zincrich
Fosroc Solvent 102

:
:

16C
33C

For further information, refer to the Product Material Safety


Data Sheet.

* Denotes the trademark of Fosroc International Limited

See separate data sheet

Important note
Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard
Conditions for the Supply of Goods and Service. All Fosroc datasheets are updated on a regular basis. It is the users
responsibility to obtain the recent version. Refer to www.fosroc.com.

Al Gurg Fosroc
LLC
Post Box 657, Dubai
United Arab Emirates

www.fosroc.com

Head Office
telephone: (+9714) 2039699

fax: (+9714) 2859649

email: agf@fosroc.com

Regional offices
Dubai, Al Gurg Fosroc

telephone: 285 8787

fax: 285 2023

email: dubai@fosroc.com

Abu Dhabi, Al Gurg Fosroc


Bahrain, YBA Kanoo

telephone: 673 1779


telephone: 17735454

fax: 673 1449


fax: 17732828

email: abudhabi@fosroc.com
email: bahrain@fosroc.com

Kuwait, Boodai
Oman, Al Amana
Qatar, Tadmur

telephone: 4817618
telephone: 771 5080
telephone: 4500607

fax: 4832124
fax: 771 7554
fax: 4500543

email: kuwait@fosroc.com
email: oman@fosroc.com
email: qatar@fosroc.com

UAE/0318/01/B